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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1306 (Engine Controls And Fuel - 6.6L - Introduction (1 Of 2)) >> Repair Instructions >> Exhaust Gas Recirculation Valve Cooler Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying EGR Valve & Mounting Bolts
    GM1867258Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. If the EGR valve cooler was replaced, perform the following steps:
    1. Position the EGR valve (3) to the cooler.
    2. Install the EGR valve bolts (2).

      Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    3. Install the EGR valve cooler hose (4) and position the hose clamp.
    4. Install NEW EGR valve gaskets (1).
    2. Fig 2: Identifying Fuel Injection Fuel Feed Manifold Bolt, Fuel Feed Pipe Nut & EGR Brackets
    GM1867255Courtesy of GENERAL MOTORS CORP.
  2. If necessary, perform the following steps in order to install the EGR brackets:
    1. Position the EGR brackets (4).
    2. Install the EGR bracket bolt (2).

      Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    3. Position the clip and install the fuel feed pipe nut (1).

      Tighten:  Tighten the nut to 25 N.m (18 lb ft).

    4. Install the fuel injection fuel feed manifold bolt (3).

      Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    3. Fig 3: Identifying EGR Valve Cooler, Gasket & EGR Temperature Sensors
    GM1998504Courtesy of GENERAL MOTORS CORP.
  3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine.
  4. Install the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1  or Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 .
    5. Fig 4: View Of EGR Valve Cooler & Bolts
    GM1873275Courtesy of GENERAL MOTORS CORP.
  5. Install the front EGR valve cooler bolts (1).

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    6. Fig 5: View Of EGR Valve Cooler Bolts & Nuts
    GM1873274Courtesy of GENERAL MOTORS CORP.
  6. Install the rear EGR valve cooler bolts (1).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  7. Install the right exhaust pipe to EGR valve cooler nuts (2).

    Tighten:  Tighten the nuts to 53 N.m (39 lb ft).

    8. Fig 6: View Of EGR Valve Cooler Coolant Hose Clamp & Nut
    GM1873269Courtesy of GENERAL MOTORS CORP.
  8. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler.
  9. Position the EGR valve cooler coolant hose clamp (1).
  10. Install the EGR valve cooler coolant hose clamp nut (2).

    Tighten:  Tighten the nut to 24 N.m (18 lb ft).

    11. Fig 7: View Of Heater Inlet Hose Clamp
    GM1873268Courtesy of GENERAL MOTORS CORP.
  11. Position the heater inlet hose and install the hose to the EGR valve cooler.
  12. Position the heater inlet hose clamp (1) at the EGR valve cooler.
  13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  14. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  15. Install the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement .
  16. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) or Cooling System Draining and Filling (Static Fill) .
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